Introduction To Industry Scenarios
The core of glass manufacturing is melting at 1500 ℃ in a melting furnace, forming a tin bath, annealing in an annealing furnace, and cutting. The working conditions include ultra-high temperature, strong corrosion, dust, steam, vibration, electromagnetic interference, and 24-hour continuous operation.
Typical measuring points:
Melting furnace: kiln pressure (micro positive pressure), glass liquid level, fuel (natural gas/heavy oil) pressure, combustion air pressure, cooling air pressure
Tin bath: Tin liquid level, protective gas (nitrogen/hydrogen) pressure, cooling water pressure/level
Annealing kiln: kiln pressure, cooling air pressure, roller lubrication station oil level
Raw material ingredients: quartz sand/soda ash silo level, slurry pool level, mixer pressure
Public auxiliary/environmental protection: sewage treatment tank level, acid and alkali storage tank level, compressed air pressure, fire water tank level
Adapt to Core Products
QDY30A ultra-high temperature anti-corrosion type input type liquid level transmitter (200 ℃, resistant to glass liquid corrosion, 316L/Hastelloy alloy IP68、 Tin bath specific)
QDY60 series static pressure liquid level transmitter for raw materials/glass slurry (anti dust/powder, anti clogging, long-term immersion, special for raw material warehouse)
QDW90A-3051 special flange liquid level transmitter for melting furnace/tin bath (200 ℃, flat diaphragm anti sticking glass liquid, special for high-temperature viscous media)
QDKG ultra-high temperature anti-corrosion intelligent pressure switch/transmitter (0.075 level, 200 ℃, explosion-proof Ex d II CT6, acid and alkali resistant, dedicated for melting furnace pressure)
GLG ultra-high temperature strong interference signal isolator/RS485 (2500V isolation, resistant to high current/frequency converter interference, long-distance transmission)
S803/SS803 ultra-high temperature anti-corrosion digital display instrument (IP65, high temperature/steam resistance, 316 stainless steel shell, local alarm, furnace/tin tank wall mounted)
Product Function
QDY30A/QDY60+QDW90A-3051 liquid level type (melting furnace/tin tank/raw material warehouse)
Melting furnace glass liquid level: QDW90A ultra-high temperature, flat film anti sticking glass liquid, precise control of glass liquid level, ensuring uniform discharge, stable glass thickness, reducing thickness difference/corrugation defects, and improving yield rate.
Tin bath tin liquid level: resistant to high temperature, oxidation, and corrosion. Monitor the tin liquid level, link the tin liquid replenishment pump to ensure stable depth of the tin liquid, smooth glass ribbon, and reduce deformation/warping.
Raw material warehouse (quartz sand/soda ash) material level: prevents dust accumulation, long-term stability, monitors the material level in the warehouse, links the feeding/discharging belts, prevents material breakage/tank overflow, ensures accurate batching, and stable glass composition.
Cooling water level for tin bath/annealing kiln: high temperature resistance, anti scaling, real-time monitoring of cooling water volume, prevention of water shortage and burning of tin bath/annealing kiln, ensuring stable forming and extending equipment life.
QDKG ultra-high temperature anti-corrosion pressure switch/transmitter (kiln pressure/air pressure/oil pressure)
Melting furnace pressure (micro positive pressure): 0.075 level, ultra-high temperature, explosion-proof, precise control of kiln pressure micro positive pressure, preventing cold air from entering the kiln for cooling, preventing hot gas from leaking and burning refractory bricks, reducing energy consumption, and extending the life of the melting furnace (5-8 years).
Tin bath protection gas pressure: anti-corrosion, micro pressure type, stable nitrogen/hydrogen pressure, prevents tin liquid oxidation, reduces tin slag, and improves glass surface quality.
Fuel/Combustion Air Pressure: High temperature and pressure resistant type, monitoring natural gas/heavy oil/combustion air pressure to ensure stable combustion, uniform kiln temperature, and reduce bubble/stone defects.
Roller lubrication station pressure: high-precision, anti vibration, monitoring oil pressure, preventing oil shortage from burning the roller, ensuring annealing stability, and reducing glass scratches.
GLG ultra-high temperature strong interference isolator (strong interference from melting furnace/tin bath)
Furnace/tin bath high current/frequency converter interference: 2500V isolation, common mode rejection ≥ 60dB, cutting off ground loop, suppressing peak interference, DCS signal no drift/jump, no false interlocking, ensuring continuous production.
Long distance signal (melting furnace → central control/tin tank → scheduling): RS485+Modbus, signal attenuation free, packet loss rate<0.1%, real-time data upload, stable traceability.
S803/SS803 ultra-high temperature anti-corrosion digital display instrument (on-site/furnace wall mounted)
On site display of melting furnace/tin bath: IP65 high temperature steam resistance, high brightness LED, anti-corrosion, intuitive reading during inspection, no need to enter ultra-high temperature areas, safe and efficient.
Over limit alarm/interlock: relay output, linked sound and light alarm, emergency stop/valve closing, 1-second response, preventing overpressure/water/material breakage accidents.
Data upload/accumulation: Modbus communication, connected to glass MES system, energy/raw material consumption statistics, fault tracing, meeting the requirements of intelligent manufacturing in the glass industry.
Addressing Industry Issues
Ultra high temperature+strong corrosion+steam, extremely short instrument lif
Ordinary instruments corrode/adhere/damage within 1-3 months, frequent shutdowns for replacement, affecting continuous production, and high maintenance costs.
Inaccurate control of kiln pressure/glass liquid level, multiple quality defects
Large fluctuations in kiln pressure, heat leakage/cold air intake, high energy consumption; The glass liquid level is unstable due to differences in thickness, wave reinforcement, and bubbles, resulting in a low yield rate.
Strong electromagnetic interference, signal jumping and false interlocking
High current/frequency converter interference, DCS false alarm, false shutdown, material breakage/kiln overflow, single accident losses of tens of millions.
Danger of manual patrol inspection+low efficiency
High temperature of 1500 ℃ in the furnace, toxic gas in the tin bath, high risk of manual liquid level measurement/meter reading, low efficiency, data lag, and untimely adjustment.
Inaccurate raw material ingredients and fluctuations in glass composition
Inaccurate monitoring of material levels, large errors in ingredient preparation, unstable glass composition, substandard strength/transparency, and numerous customer complaints.
Direct Customer Benefits
Quality and yield return (core)
Accurate control of glass liquid level/kiln pressure: glass thickness difference/corrugation/bubble defects are reduced by ≥ 85%, yield rate is increased by 5% -8%, and annual production of high-quality glass is increased by ≥ 100000 weight boxes.
Accurate ingredients: The stability of glass composition is improved by ≥ 95%, the compliance rate of strength/transmittance is ≥ 99%, and customer complaints are reduced by ≥ 90%.
Energy conservation, consumption reduction, and lifespan benefits
Stable kiln pressure: The natural gas consumption per ton of glass is reduced by 4% -6%, and the annual production of 5 million weight boxes of glass factory is ≥ 2 million m ³, saving gas costs ≥ 4 million yuan.
Extension of furnace life: Stable kiln pressure reduces erosion of refractory bricks, prolongs furnace life by 2-3 years, and reduces annual maintenance costs by ≥ 5 million yuan.
Optimization of tin bath protection: Ensure stable gas pressure, reduce tin slag production by ≥ 70%, and save tin ingot costs by ≥ 800000 yuan annually.
Safety and continuous operation benefits
Ultra high temperature explosion-proof+isolation: The risk of furnace sparks is reduced to 0, and the safety accident rate is reduced by ≥ 98%.
Instrument high reliability: failure rate reduced by ≥ 90%, unplanned downtime reduced by ≥ 95%, annual avoided downtime loss ≥ 8 million yuan.
Maintenance and labor benefits
High reliability design: The instrument has a lifespan of 2-3 years, with annual maintenance costs reduced by ≥ 80% and spare parts/labor expenses reduced by ≥ 600000 yuan.
Unmanned operation: Reduce manual inspection by ≥ 85%, save labor costs of ≥ 250000 yuan per year, and eliminate the risk of ultra-high temperature/toxic operations.
Management and compliance benefits
Accurate and traceable data: meets the requirements of glass MES/ISO system, the data is authentic and tamper proof, and improves the level of management refinement.
Intelligent upgrade: Connected to the smart glass platform, remote monitoring/scheduling, management efficiency improved by ≥ 60%, in line with national glass intelligent manufacturing and green low-carbon policies.
